I'm itching to give it a go but need a new tip on the cutter first... so, before I give it a go is it actually possible, or am I wasting my time?

Was thinking of cutting some 5mm, maybe 10mm for a bellhousing adapter.

Then I need some ali welding......

yep done it, seems wrong but it works brilliantly.

yep it can be done,

I cut my side panels out using mine, only 1mm or so thick, so went through a 2m sheet in about 10 secs, dead easy and nice straight line,

Tried doing some 3mm thick and it did that OK, just make sure your compressor is always close to full, i was running out of pressure and the cuts started to get worse and worse and take longer to go through

Yep me too! works very well, I have also cut 3mm stainless steel plate with one, but it's not too pretty!